Method and apparatus for trimming a sample from a coiled metal web

ABSTRACT

Sample extraction or trimming from an end strip of an elongated formed metal that is coiled in layers within a tensioned metal coil resting on driven rollers. A cut channel is formed across the material width. In some embodiments the cut channel is formed between the rollers and by cutting at an angle relative to the coil outer surface. Coil weight and/or a coil tensioner mechanism inhibits coil relaxation along the cut channel by maintaining tension on wrapped layers against each other when the coil is unbanded for sample extraction. The coil is rotated so that the cut channel clears the rollers laterally. Material downstream the cut is then separated from the coil. After trimming and/or sample extraction the coil maintains rolled tautness for ease of rebanding.

CLAIM TO PRIORITY

This application claims the benefit of two co-pending United Statesprovisional patent applications, respectively entitled: “Automated HeavyGauge Sampling Station”, filed, Jan. 20, 2011, and assigned Ser. No.61/434,630 and “Method and Apparatus for Trimming a Sample from a CoiledMetal Web”, filed, May 23, 2011, and assigned Ser. No. 61/488,874; bothof which are incorporated by reference herein.

BACKGROUND

1. Field

Embodiments of the present invention relate to trimming ends from a coilof coiled formed metal without distorting the material remaining on thecoil and maintaining the coil layers tightly wrapped in taut tension forbanding or rebanding. Coil ends are trimmed for obtaining test andinspection samples, as well as for trimming scrap tail ends.

2. Description of the Prior Art

A known system places a banded metal coil of tightly wrapped formedelongated sheet material (e.g., a sheet web) between spaced parallelrollers, removes bands that maintain coiled metal layers in a tightlywrapped, taut layer condition, and thereafter unwinds a portion of thecoil end so that a desired length extends generally tangentially fromthe coil laterally clear from the rollers. The tangential end isselectively cut through the full material thickness normal to itssurface by a shear. The sheared-off tangential end separates from theroll and drops into a collection container. A remnant stub projectsgenerally tangentially from the roller in a relaxed uncoiled deformedstate that inhibits tight re-rolling and banding of the sampled coil.The sheared edge remaining on the coil may have localized distortion anda relatively blunt edge generally along the coil's radial circumferencethat may hinder further rotational maneuvering of the coil on therollers. The known sampling system is monitored and controlled by ahuman operator.

SUMMARY

Accordingly, embodiments of the present invention include the creation acoil trimming and sampling system that, in one aspect reduces and in yetanother prevents deformation of the coil material dimensions during thetrimming or sampling procedure, and facilitates rebanding of the coil inits taut, fully coiled state.

Another embodiment of the present invention includes a coil trimming andsampling system that facilitates a clean separation of the coil samplefrom the coil while minimizing localized coil material dimensionaldeformation along the separation edge.

An additional embodiment of the present invention includes a coiltrimming and sampling system that facilitates passage of the separationedge remaining on the coil over the rollers as the coil is manipulated,including for re-strapping the coil in it tensioned wrapped state.

Another exemplary embodiment includes an automated trimming and sampleextraction system and method that does not require human interventionbetween sampling steps.

These and other embodiments can be achieved by a system and method fortrimming or extracting a sample from the end of a metal coil. Ends aretrimmed and/or samples are extracted from an end strip of a tensionedmetal coil that is resting on rollers. In one embodiment, a cut channelis formed between the rollers by cutting at an angle relative to thecoil outer surface. Coil weight inhibits coil relaxation along the cutchannel. The coil can be rotated so that the cut channel clears therollers laterally and the scrap end or sample downstream the cut channelis separated off the coil.

In embodiments of the present invention, cut channel depth and angle maybe selected so that the trimmed/sampled end's full material thickness isnot penetrated. The uncut necked material thickness remaining at thedepth of the cut channel formation is selected to allow a cleanseparation of the material. Angular cutting reduces deformation of thematerial along the edge remaining on the coil and reduces the forcerequired to separate the strip downstream the cut channel. If theseparation force is less than the material's tensile strength there isless likelihood that the edge will be deformed. After sample extractionthe coil maintains rolled tautness for ease of rebanding.

Embodiments of the present invention include sampling systems forextracting a sample from an end strip of a coil having wrapped layers ofcoiled formed elongated metal. The system has a pair of generallyparallel spaced drive rollers that are driven by a roller drive systemcoupled thereto, for selective rotation of a coil about a coil centralaxis that is oriented parallel to the rollers. A cutter is proximal therollers for alignment with a circumference of a metal coil resting onthe driven rollers. The cutter has a cutter drive mechanism forselectively advancing the cutter into the coil and selectivelytraversing the cutter along the coil circumference. A coil tensionermechanism maintains tension on wrapped layers against each other in ametal coil resting on the rollers, in order to inhibit relaxation of thecoiled layers.

Embodiments of the present invention additionally include a method forextracting a sample form an end strip of a coil having wrapped layers ofcoiled formed elongated metal with a sampling system. The method isperformed by placing a banded coil, having a central axis, on a pair ofgenerally parallel spaced driven rollers so that the coil central axisis oriented parallel to the driven rollers. Tension is maintainedbetween wrapped layers in the coil against each other with a coiltensioner, so that the coil can be unbanded without disturbing thetensioned layers. The coil is rotated with the driven rollers so that adesired length of end strip is oriented downstream the cutter. The endstrip material is cut by selectively advancing and traversing the cutterinto the coil in any desired sequence. The end strip is then extractedfrom the coil.

Further features of embodiments of the present invention, and theadvantages offered thereby, are explained in greater detail hereinafterwith reference to specific embodiments illustrated in the accompanyingdrawings, wherein like elements are indicated by like referencedesignators.

BRIEF DESCRIPTION OF THE DRAWINGS

The teachings of the present invention can be readily understood byconsidering the following detailed description in conjunction with theaccompanying drawings, in which:

FIG. 1 is a perspective view of a system loaded with a metal coil, inaccordance with an exemplary embodiment of the present invention;

FIG. 2 is a perspective view of the system of FIG. 1 without a metalcoil, in accordance with an exemplary embodiment of the presentinvention;

FIG. 3 is a front elevational view of a coil sample cutter, inaccordance with an exemplary embodiment of the present invention;

FIG. 4 is a detailed view of FIG. 3, in accordance with an exemplaryembodiment of the present invention;

FIG. 5 is a longitudinal sectional view of a coil sheet showing cuttingangle and profile made by the coil sample cutter, in accordance with anexemplary embodiment of the present invention;

FIGS. 6A-6D is a series of schematic end views showing coil rotationalpositions during steps of a sampling method, in accordance with anexemplary embodiment of the present invention;

FIG. 7 shows exemplary coil rotational positions for two coil diameters,in accordance with an exemplary embodiment of the present invention;

FIG. 8 is a schematic side elevational view of a system loaded with ametal coil, in accordance with another exemplary embodiment of thepresent invention;

FIG. 9 is a schematic side elevational view of a system loaded with ametal coil, in accordance with an additional exemplary embodiment of thepresent invention, prior to coil clamping;

FIG. 10 is a schematic side elevational view of a system loaded with ametal coil, similar to that of FIG. 9, wherein the coil is clampedwithin the sampling system.

FIG. 11 is a partial cross-sectional plan view of the system of FIG. 10,taken along 11-11 thereof; and

FIG. 12 is a schematic diagram of an automation system for operating thesystem, in accordance with an exemplary embodiment of the presentinvention.

To facilitate understanding, identical reference numerals have beenused, where possible, to designate identical elements that are common tothe figures.

DETAILED DESCRIPTION

After considering the following description, those skilled in the artwill clearly realize that the teachings of my invention can be readilyutilized in coiled metal sample extraction systems and methods.

General System Overview

Referring generally to FIGS. 1 and 2, showing one exemplary embodimentof the present invention, a coiled metal web 10 is placed in a sampleextraction system 20, where it rests on at least a pair of drivenrollers 22, in an exemplary embodiment there are two driven rollers asillustrated in FIGS. 1 and 2, that are capable of causing rotation ofthe coil about its central rotational axis. While coiled sheet web isshown in the figures herein, other types of elongated coiled formedmetal may be accommodated in the sampling system of the presentinvention, including by way of nonlimiting example rebar, round orrectangular barstock, pipe and tubing. A sample cutter 30 can bepositioned parallel to and between the rollers 22, as well as the coil10 central rotational axis. The sample cutter 30 is driven by a lineardrive 24 along the X axis transverse the coiled sheet web.

Referring to FIGS. 3 and 4, the sample cutter 30 includes a carriage 32capable of being radially extended along axis D. The sample cutter 30has a cutter head 34 that is driven by a motor 36. The sample cutterhead 34 is pivoted about the X axis through an angular range of motionθ. A disc-type slot milling tool may be used for the cutter head 34. Thecutter head 34 or other cutting tool can have many desired cutting tipprofile, including without limitation rectangular, triangular or otherpointed tip, radiused-edge rounded lateral ends, arcuate, semi-circular,or oval profiles. Alternative cutting devices may be utilized, such asby way of non-limiting example plasma or electric discharge machining(EDM) heating cutters, broaching cutters or shears. At least one pair ofrollers 38 can contact the outer circumferential surface of the coil 10.A proximity sensor 40 can confirm that the sample cutter carriage can bein contact position with the coil 10, and a thickness gauge sensor 42 isadapted to determine the thickness of the coil sheet material atmultiple positions across the coil width. Information from a pair ofsensors 40, 42 may be communicated to an automated control system forautomatic operation of the system, as will be explained in greaterdetail herein. For example, the automated control system can determinethe average material thickness based on the thickness gauge sensor 42sample readings. As illustrated, the cutter head 34 cuts transverselyacross the coil sheet web parallel to the coil rotational axis, but onemay chose to skew the cut along any desired transverse angle or employ anon-linear cutting path. By cutting between the rollers 22, the coilweight maintains relative pressure between the cutter head 34 and thesheet web, thereby maintaining the web in taut coiled condition.

As shown in FIG. 5, the cutter head 34 can be positioned in such a wayto create a cut channel of angle θ and radial depth D into the sheetthickness, leaving a thin neck of material at the base of the cutchannel. Cut angle θ and depth D are chosen so that the sheet material11 downstream of the coil may be separated from the main coil 10 withoutunduly distorting the cut edge remaining on the coil, or leaving ajagged edge. Web material composition, hardness, and thickness may beused as factors for determining cut angle θ and depth D. The partial cutthrough the sheet thickness can reduce the force necessary to separatethe remnant 11 downstream the cut from the rest of the roll after itlaterally clears the driven rollers 22, but while the piece remainsintact with both sides maintaining the same thickness it is easier topass them over the rollers. The cut angle θ can be set at zero degrees,orienting the cutting head 34 normal to the coil 10 web. The cut depth Dcan be chosen to cut all the way through the coil 10 web, so that thereis no partial cut. Where no partial cut is desired a cutting head 34′,having a triangular or other cross-sectional profile that tapers orotherwise necks to a narrower tip may be utilized, as shown in FIG. 7.

By cutting the coil sheet material at an angle θ greater than zerodegrees, cut depth D may be approximated to be slightly less than theweb thickness, in order to avoid damaging the web layer underlying thecut zone. In this way tolerance variations in either material webthickness (thinner range of acceptable variation) and/or the cut depth(deeper depth range) will not unduly risk cutting through the entire weband damaging the underlying web layer. Conversely, if the web is at thethicker range of acceptable variation and/or cut depth is in theshallower range, the web neck thickness at the bottom of the cut troughwill still be sufficiently thin to facilitate “clean” separation of thesample 11 from the coil 10. Cut angle θ may be generally limited toapproximately 30 degrees, with 15 degree cut angle being sufficient forsteel sheet of Rockwell C hardness between 17 and 32. Cutting depth D ischosen so that the remaining web neck at the bottom of the cuttingtrough is less than 0.5 mm (0.020 inches), with 0.35 mm (0.015 inch)being satisfactory for the same hardness range steel. Angle and cuttingdepth of the trough may be varied for different materials and hardnessat the discretion of one skilled in the art.

System General Operation

Referring to FIGS. 6-9, when the coil 10 is positioned between thedriven rollers 22, the angular position α of the web end can bedetermined. The coil 10 is rotated by the rollers 22 so that the web endis a desired number of angular degrees away from the cutting head 34that corresponds to the desired circumferential length of the sample tobe cut from the coil. Using the example of FIG. 7, if one wishes to cutan approximate 61 cm (˜24 inch) sample from an approximate 206 cm (˜81inch) diameter coil 10, the coil end can be rotated so that a equalsapproximately 34 degrees relative to the cutting head 34′. Anapproximate 107 cm (˜42 inch) diameter coil, however, can be rotated sothat a equals approximately 67 degrees relative to the cutting head 34′,to create the same length sample.

In the exemplary system operational sequence of FIGS. 6A-6D, anapproximate 61 cm (˜24 inch) long scrap remnant 11 is first cut from thecoil 10, and then an approximately 51 cm (˜20 inch) long circumferentialsample can be cut from the coil. In order to cut the scrap, theapproximately 81 inch diameter coil can be initially rotated to alignthat end is approximately 34 degrees (α) downstream from (i.e., to theleft of) the cutter head 34, as shown in FIG. 6A. The cut trough isformed in the web by the cutter head 34, whereupon the coil 10 isrotated clockwise or downstream from the cutter head, so that the cut islaterally clear of its proximal roller 22. In this position the scrapremnant 11 is no longer taut on the coil 10 and relaxes to projectgenerally tangentially from the coil surface. A peeler 50, (for examplethe robot 50 shown in FIGS. 9 and 10) can shear the scrap generallytangentially relative to the coil 10 surface and breaks the scrap offfrom the coil along the cut trough narrowed neck.

After the scrap piece is removed, the coil 10 is rotated sufficientlyclockwise or counterclockwise, as necessary, to set the desired lengthof the sample piece remnant 12 (in the present example, approximately 51cm or ˜20 inches) at approximately 32 degrees of angular rotation arelative to the cutter head 34. The next cut trough is created and thecoil again rotated clockwise so that the sample piece 12 projectstangentially downstream from the coil outside the proximal roller 22,whereupon peeler 50 separates the sample from the coil. The cut channelcreated when making the angular cut facilitates smooth passage of thestill unitized sheet material (with effectively no discontinuity inthickness) over the driven rollers 22 in either rotational direction.After the sample 12 is removed from the coil 10, it can be rebandedmanually while on the sampling system. Alternatively, the unbanded coil10 can be collected by a coil car and transfer device and banded at aseparate station. While in this exemplary operational description ascrap remnant 11 was first cut from the coil 10 prior to cutting asample remnant 12, one may choose to dispense with the need to removescrap from the coil 10 end, or alternatively, unspool additional webmaterial from the coil 10 before taking one or more samples. Forexample, if the coil sample is not on gauge or within tolerance for thegauge required at the proposed cutting position, then a cut can be madeand the coil rotated to a new position where the coil is on gauge. Thesample can then be taken at this new position.

An alternate embodiment sampling system 20′ is shown in FIG. 8. In thisembodiment the coil 10 can be repositioned vertically in the Y axisdimension by roll alignment lift mechanism 60. The lift mechanism 60includes a roll support saddle 62 that supports the driven rollers 22. Ahydraulic lift 64 can raise and lower the support saddle 62 so that acoil 10 or smaller diameter coil 10′ can be positioned relative tocutter 30′. In this embodiment, cutting head 34 is aligned with theradial circumference of coil 10 or 10′ at a 9 o'clock relative positionrather than at a 6 o'clock position of the previous embodiment of FIGS.1-7.

The cutter 30′ can translate across the X or axial dimension of the coil10, 10′ on linear drive 24′. The cutter 30′ is constructed and operatesthe same as the previously described cutter 30 of the sampling system20, but as previously noted, aligns the cutting head 34 at the 9 o'clockposition rather than at the 6 o'clock position between the rollers 22.The cutter 30′ may be aligned radially along the coil 10, 10′circumference at any desired position by repositioning the rollalignment lift mechanism 60 up or down in the Y direction and pivotingthe cutting head 34 relative to the coil along angle θ.

A coil tensioner mechanism 70 is adapted to maintain tension on wrappedlayers against each other by exerting radially inwardly directedcompressive (i.e., squeezing or clamping) tension on the coil 10 or 10′.The coil tensioner 70 inhibits coil relaxation that will otherwisedisrupt desired taut tensioning of the coiled web when the web usunwound for cutting. By compressing or squeezing/clamping wrapped coilweb layers against each other, web material upstream of the coiltensioner mechanism 70 remains tightly coiled and taut. While a coiltensioner mechanism 70 not shown in the sampling system 20 embodiment,such a mechanism may be used in that embodiment system in order toprovide additional coiling tension. The coil tensioner mechanism 70 hasa support stanchion 72 is shown coupled to the support saddle 62, sothat it moves with a coil 10 supported within the lift mechanism 60.Alternatively, the stanchion 72 does not need to be attached to the liftmechanism 60, and may for example be affixed to the factory floor withits own mechanism to move in coordination with the coil 10 in the Y orvertical dimension. The coil tensioner mechanism 70 includes a boom 76pivotally coupled to the stanchion 72 by pin 74, so that the boom pivotsalong an angular path 13. Tensioner roller 78 is rotatively coupled tothe distal end of the boom 76, and exerts radially inwardly biasedcompressive force on the coil 10 by actuation of hydraulic cylinder 80,so that the coil 10 is compressed between the rollers 22 and thetensioner roller.

FIGS. 9-11 show another embodiment sampling system 20″. In thisembodiment the cutter 30″ is driven on wheels 24″ in the Z accessdirection that is perpendicular to the coil 10 outer circumference. Thecutter 30″ has a cutter clamp 92, which is an elongated bar spanningacross the axial length of the coil 10, having a cutter slot 94 forpassage of cutter head 34 therethrough. The cutting head can be drivenalong a track in the cutter 30″ across cutter slot 94 in the X axis toform a traversing cut across the coil 10 outer circumference. Cutterclamp 92 reciprocates in the Z axis direction (toward or away from thecoil 10), driven by hydraulic cylinders 82 and piston rods 84 that arecoupled thereto. Cutter 30″ also has an elongated bar or bumper-likepeeler clamp 96 affixed thereto that traverses the coil 10 outercircumference, for abutment against the coil 10 outer circumference asthe cutter is translated in the Z access direction. The peeler clamp 96has a tapered bottom edge to facilitate extension of a scrap end remnant11 (or sample end remnant 12) thereover and a clearance slot 98traversing the clamp.

In operation of the sampling system 20″ the cutter 30″ is abutted tocontact against the coil 10, and the cutter clamp 92 is withdrawn in theZ direction away from the coil 10, creating an opening gap betweenitself and the peeler clamp 96. Next, the coil 10 end remnant (e.g.,scrap 11 or sample 12 end) is threaded through that gap by rotating thecoil clockwise with the rollers 22, so that the coil end remnant ridesover the peeler clamp 96 tapered bottom edge. When a desired length ofthe coil 10 end extends downstream of the cutter head, e.g., by rotatingthe coil 10 a desired number of degrees a with the rollers 22, cutterclamp 92 is reciprocated toward peeler clamp 96, effectively squeezingor tensioning the coil end therebetween as a coil tensioner mechanism.Cutter head 34 is advanced into the coil 10 material in the D directionand traversed across a desired axial width of the material in the X axisdirection (e.g., across the entire material width in order to facilitateremoval of a scrap end 11 sample 12. Cutter head 34 may be advanced orretracted in the D direction by a separate drive axis, or may bemanually set by pre-extending it into the cutter clamp 92 cutter slot94, so that a desired depth cut is formed in the coil 10 material. Cutdepth into the coil 10 web material may be selectively set as a partialcut or a full through cut. Notch 98 formed in the peeler clamp 96 allowscutter head 34 clearance if the cutter head is extended beyond the webmaterial through cut depth. Robot 50 is a peeler mechanism to grab thefree end of the cut scrap end 11 or sample end 12. If a through cut isperformed the robot 50 holds the end 11 or 12 and can transport the endto a desired location. If a partial cut is performed in the end 11 or12, the robot 50 can be used to snap the remnant end off the webmaterial remaining on coil 10. After cut completion and removal of theend 11 or 12, remaining web material on the coil 10 can be prepared forrebanding by counter rotating the coil in the counterclockwise directionso that the remaining coil free end is proximal or under one of therollers 22. While not shown, the tensioner mechanism 70 may be used withthe sampling system 20″ embodiment.

The sampling system embodiments 20, 20′, 20″ may be incorporated into afully automated sampling system. Referring to FIG. 9 automated controlsystem 100 includes a communication bus 110 communicatively coupled to acontroller having a processor including accessible memory, such asprogrammable logic controller (PLC) 120 with memory 122. An exemplarybus 110 communication protocol is industrial Ethernet. The memory 122includes software and/or firmware instruction sets stored therein thatwhen executed by the PLC processor controls operation of system drives130 and communications cards 140 that are in communication with thesystem 20, 20′, 20″ including: its driven rollers, the cutter 30, 30′,30″, sensors such as the coil proximity sensor 40 and thickness gaugesensor 42, the sample peeler (e.g., robot) 50, the roll alignment lift60 and the coil tensioner mechanism 70. Communication and control amongthe PLC 120, the system drives 130, communication cards 140 and devicescoupled thereto is established via a suitable industrial control busprotocol, such as Profibus DP protocol available through the owner ofthis filed application. The PLC 120 may be in communication via bus 110with an engineering station 150 for monitoring and altering systemoperational parameters. A human machine interface (HMI) 160 may also bein communication with the system 100 to enable manual control andmonitoring by factory personnel on the shop floor or remote operationalstation.

Although various embodiments which incorporate the teachings of thepresent invention have been shown and described in detail herein, thoseskilled in the art can readily devise many other varied embodiments thatstill incorporate these teachings.

1. A sampling system for extracting a sample from an end strip of a coilhaving wrapped layers of coiled formed elongated metal, comprising: apair of generally parallel spaced drive rollers that are driven by aroller drive system coupled thereto, for selective rotation of a coilabout a coil central axis that is oriented parallel to the rollers; acutter, proximal the rollers, for alignment with a circumference of ametal coil resting on the driven rollers, the cutter having a cutterdrive mechanism for selectively advancing the cutter into the coil andselectively traversing the cutter along the coil circumference; and acoil tensioner mechanism for maintaining tension on wrapped layersagainst each other in a metal coil resting on the rollers, in order toinhibit relaxation of the layers.
 2. The system of claim 1, the cutterfurther comprising a metal cutting device selected from the groupconsisting of milling tool cutters, shears, plasma heating cutters,electric discharge machining (EDM) cutters and broaching cutters.
 3. Thesystem of claim 2, wherein the cutter is a disc-type slot milling toolcutter having a cutting profile selected from the group consisting ofrectangular, radiused edge, ball, triangular and necked distal tipprofiles.
 4. The system of claim 1, wherein the cutter drive mechanismorients the cutter so that it is capable of selectively forming a cutchannel within a layer of the coiled metal at a range of angles fromzero to ninety degrees relative to a coil radius, and a selective rangeof cut depths up to and including through entire thickness of a layer ofthe coiled metal.
 5. The system of claim 1, wherein the cutter drivemechanism orients the cutter so that it is capable of selectivelyforming a cut channel within the coil metal traversing axially across atleast a portion of the coil.
 6. The system of claim 1, wherein thecutter is oriented under and between the driven rollers, and the drivenrollers are the coil tensioner mechanism.
 7. The system of claim 1,wherein the coil tensioner mechanism comprises a biased tensioner rolleroriented above the driven rollers, for compressing wrapped layers of ametal coil resting on the rollers.
 8. The system of claim 1 furthercomprising a lift mechanism coupled to the driven rollers, forselectively varying roller height relative to the cutter.
 9. The systemof claim 1 further comprising an automated control system coupled to thedriven rollers and cutter drive systems for selectively extracting asample from an end strip of a coil placed on the rollers without humanoperator intervention.
 10. A method for extracting a sample form an endstrip of a coil having wrapped layers of coiled formed elongated metal,comprising: placing a banded coil, having a central axis, on a pair ofgenerally parallel spaced driven rollers so that the coil central axisis oriented parallel to the driven rollers; maintaining tension onwrapped layers in the coil against each other with a coil tensionermechanism and unbanding the coil; rotating the coil with the drivenrollers so that a desired length of a coil end strip is orienteddownstream a cutter that is proximal the driven rollers; cutting the endstrip by selectively advancing and traversing the cutter into the coilin any desired sequence; and extracting the end strip from the coil. 11.The method of claim 10, further comprising rebanding the coil after theextracting step.
 12. The method of claim 10, wherein the cutter isoriented under and between the driven rollers, and the driven rollersare the coil tensioner mechanism by weight of the coil compressing thecoil layers against the driven rollers.
 13. The method of claim 10wherein the coil tensioner mechanism is a biased tensioner rolleroriented to compress a coil placed in the sampling system between itselfand the driven rollers.
 14. The method of claim 10, wherein the cuttingstep further comprises selectively forming a cut channel within a layerof the coiled metal at a range of angles from zero to ninety degreesrelative to a coil radius, and a selective range of cut depths up to andincluding through entire thickness of a layer of the coiled metal byorienting the cutter with the drive mechanism.
 15. The method of claim14, wherein the cut channel angle is between approximately 15-30 degreesand cutting depth is sufficiently shallow to leave a remaining thicknessof uncut metal in the layer less than 0.5 millimeters (0.020 inch). 16.The method of claim 14, wherein the cutting step further comprisesselectively traversing the cutter axially across the entire layer inorder to extract the end strip from the coil during the extracting step.17. The method of claim 11, wherein the cutter further comprises a metalcutting device selected from the group consisting of milling toolcutters; shears; plasma heating cutters; electric discharge machining(EDM) cutters; broaching cutters; and disc-type slot milling tool cutterhaving a cutting profile selected from the group consisting ofrectangular, radiused edge, ball, triangular and necked distal tipprofiles.
 18. The method of claim 10, wherein the system furthercomprises an automated control system coupled to the driven rollers andcutter drive systems for performing the rotating and cutting stepswithout human operator intervention.
 19. The method of claim 10, whereinthe coil tensioner mechanism comprises a pair of opposed clamps that areselectively oriented relative to each other in an open position defininga gap therebetween for receipt of material forming an end of a coiltherebetween, and a closed position that clamps the coil end materialtherebetween.
 20. The system of claim 1, wherein the coil tensionermechanism comprises a pair of opposed clamps that are selectivelyoriented relative to each other in an open position defining a gaptherebetween for receipt of material forming an end of a coiltherebetween, and a closed position that clamps the coil end materialtherebetween.